Concrete wall construction



Feb. 17,1942. F. T. FENTON 2,273,699 CONCRETE WALL CONSTRUCTION Filed Aug. 16, 1939 s Sheets-Shet 1 Feb. l7, 1942. F. T.'FENTON 2,273,699

CONCRETE WALL CONSTRUCTION Fil-ed Aug. 16, 1939" 3'Sheets-Sheet 2 F. T. FENTON CONCRETE WALL CONSTRUCTION Feb. 17, 1942.

Filed Aug. 16, 1939 3 Sheets- Sheet 3 Patented Feb. 17, 1942 UNITED STATE s PATENT;

CONCRETE WALL CONSTRUCTION I Foster T. Fenton, BaltimoreCounty, Md.

Application August 16,1939, Serial No. 290,340

4- Claims. (01. 72-46) The difiiculty incident to the plastering or concrete walls with calcium and similar plasters so as to make. building having solid concrete walls, as distinguished stuccoed walls or those having a concrete veneer which will prove satisfactory for residential and similar-purposes, is one which has presented unsurmountable difiiculties and the fact that solid concrete construction is almost unknown in calciumplastered residential and similar buildings indicates that there has never been a practical solution of this problem.

utilization of concrete in this way are, (1) the difficulty incident to attaching the plaster or any suitable plaster base to the wall, and (2) the well known hydroscopic quality of concretewhich causes a deposit of moisture on the inner surface of the concrete due to condensation and penetration and interferes with the satisfactory attachment of plaster thereto or laying of plaster thereon, and (3) that the moisture accumulated in this way tends to discolor the plaster when applied and causes it to loosen and fall, and, (4) that such buildings when and if constructed would be unsatisfactory in the average climate of the United States and Europe.

While it is obvious the inner surface of the concrete may be covered with a waterproof material, and, at considerable expense, a plaster base may be attached which thereafterprovides .for plastering, the expense of concrete construction provided in this Way is so greatly in excess of wood or of brick or concrete veneer, the latter being otherwise known as stucco, that the calcium plastered concrete construction referred to is practically unheard of and nonexistent.

The present invention is believed to completely overcome-the difficulties mentioned, providing a new type of plastered concrete wall and a method of construction, in accordance with which aplaster base Which may be of, or include both waterproof and temperature insulating materialforms the inner side of the mold or form so that as soon as the inner supports are removed, the wall;

Some of the known obstacles to the previous While various attempts have been made to exclude moisture from concrete buildings by thickening the walls, thereby greatly increasing the expense, a foot or more having been tried, without complete satisfaction, it is found that with the construction herein described and whichis the subject of this invention, satisfactorylresibuildings.

dence buildings and the like of two, threeor four stories in height withlittle, if any, reinforcement, though metallic reinforcement is not objectionable, may be constructed with the concrete portion of the walls as thin as six or even four inches, the latter for small one or two story In the accompanying drawings, '1 have illustrated improved concrete wall and the method of construction of the same:

In the drawings:

Fig. lis a fragmentary vertical transverse section on the line I--l .of Fig. 4, through the wall, immediately after pouring; the concrete may or may not be considered to have set, the forms still being in place. I

Fig. 2 is a section on line 2-2 in' Fig. 1. i Fig. 3 is a vertical section on a reduced scale of an entire wall, of two storie height and cellar. Fig. 4 is an elevation of the same looking. from the right. i

Fig. 5 is a section on the line 5- -5 in Fig. 3.

Fig. 6isa section on a reduced scale like Figs. 3 and 4, with the form removed ready toplaster.

Fig. 7 ,is an inside fragmentary elevation on a similar scale to Fig. 6, showing the wall partly plastered. a

Fig. 8 ,isan enlarged section on the line 8-8 in Fig. 7.

' Referring to the drawings by numerals, each of which is used to indicate the same or similar parts in the difierent figures, and having particular reference to Fig. 1, theconcrete wall I, which may or may not have set, the question of setting being immaterial in this illustration, is shown as enclosed between the outer form 2 and the inner form 3.

The outer form 2 consists of 2" x 4 horizontal members or walers 4, which may be of' any suitable dimensions, and 2" x 4" studs 5, whichin turn overlie the outer .form boards 6 for which purpose in accord with this practice ply woodis preferably used as it is easier to handle and'gives a smooth surface on the finished concrete.

The inner form 3' comprises walers 4 and uprightstuds 5, and in place of the usual inner form boards which are very difficult to remove as they become wedged in the concrete and are p i often destroyed in removing, the present construction includes a plaster base 1, which is essentially impervious to concrete and takes the place of the inner form boards now used in making concrete foundations, cellars and walls for other purposes. The method of application of this material to the concrete wall and the form adapted to this purpose and also the wall with the plaster base thus affixed are the important featuresof this invention. In the tests whichhave so,.far been conducted, the material known by the trade name Celotex has been used, though this is only one of several materials adapted to this purpose It is .of importance that this material must have sufficient rigidity to support the concrete between .the studs, should have waterproofing and heat insulating properties suflicient to regulatethe temperature and keep moisture which comesthrough the concrete from attacking the plaster and also at!) [keep the interior: of the building dry bypre- --:-venting condensation. 'The =material shownhas .twoiayers 1. of cellular-material between which "liS awvaterproofing sealing sheet' i. The: -im

ltprovecl construction in the preferred: form also includesion the. inner surface. of the-"mold next v to the'concrete a sheet of water proof paper-1", a .product sold under the-trade name Iceberg -,Fibre"- being. satisfactory f or: this purpose. i. In the formxof thesinven -;.the preferredconstruction ,l plasterl base 1,..and. the waterproofing material are secured to the. studs or uprights 5 -by means of double headed nails or other-suitable so =far-devised 1 the "tie. rodsas tie members 8,. which are driven ;:through. the material 1"sandthe plasterbase 7 for which purpose, inthis instance; Celotex'is used and into the studs as shownim Fig. 1 and .it;may.be considereddesirable'to drive thedouble ,aheaded nails or tie. rods 8 through anchor strips ,,9,-.; to improve the; seating of the nails --or tierods 7 i in the. concrete.

When the concrete is set, the outeriform 2.,is removed-without great difiioulty.

The removal: of the inner; ntended to be removed tion consists. .of the: supporting st greatly simplified by the substitution ter ,base.for theninner. iorm-- .iJlSBd. .iAccordirlgv to the-present invention; allthat is 5: removed, of .the innergform 1 is. the. walers '4'- and .I'thCgQSt'lldS 5'; which. -.after. the removal of the walers 4' are pulled off from the projecting ends 8C. oLthe, double. headed ends 8' projecting. The ends 8' are-then bent over on theoutside of theiplaster base-or: Celotex 'l -on the inside of.-thei room as in Figs: 7-and- 8, .so that they, serve. tolhold this plaster base material tightly in place. .Thereafter the; inner;surfaoe. of the-.concrete rwall I; is plastered inathe. well. known manner, Celotex and ,other rmaterials whichtwill support the concrete and serve as plaster-.basesbeing wisaitisfactory. the anchor nails or double headed-nails: 8.;may be of any. suitable type adapted: -to..ho1d= the.;plas- -ter base firmlyin position-if, desired metal. 1ath ;or any-suitable; lath material may be attached over i'the plaster,.'base 1 byfastening:itdonmthe Celotex or equivalent material;and passing the ..,ends 8 -of the, nails through,it;and turning them ,-.over as shown; in- Fig. 8.

ructure, is otthe plasboard previously .In t e ra t q vm t o in-the prefe red ud f. -fi t s wing-575 dorm, the; walers 4'.

tion shown which is iorm so far as it which removable por- .,nailss 8. leaving these It, is of. importance -.to.. note lthat the plaster base 1 being .crete: is. then poured attached preferably with the waterproof sheet 1" overlying the base I, the double headed nails 8 or other suitable fastenings which may have the anchor members 9 attached as illustrated are thus driven through the sheet 1" and through base 1 into uprights 5', the sheet 7" being, if desired, omitted though it adds materially to the moisture proofness and preserves the base. The outer form 2 is then set up in: the usual mannerga-fter which the conand permitted to set. The

outer form 2 is next removed. At any suitable .,.\time which may be convenient before plastering,

. the. .Walers 4'.

and plastering is proceeded with are removed. After which the upright studs5' are withdrawn from the ends 8' of the nails,- -or anchor members 8 which are turned over or utilized in any eiTective manner, in the usual ,manner, no additional plaster base being ordinarily essential or desirable.

It is of interest' that'while the-twister-ties [0 are" well" *kIlO-Wll', the mannerof -applying 4 them herein illustrated is new-and is helpful in and f to the satisfactory practice "of' this invention and of importance wherever thin -formboards-are used-making it feasible to -use-lesssubstantial formboards'thanpreviously was practicable.

These tie rods are of heavy wire iormed inter- I and:-these-1oops are en scond-ition o the form -by-=ta-ke-up wedges =1 l"- ported inthetwister brackets l I :of: the twister ties :l L is to :space -th or mold boards 6:and 1-which-a=rethe-insideof the molds by button .hold them-incontactwith the uprights 5 and '5'. -Inathespreviousapractice the twisters 10 have been-placed at convenient points al :1 4; 4' :but have not :been

rights 5; 5'.- -.:.by ..wedges ll would with the.- relatively-=thin=material used as side of l the coil --buttons H3 secured to the wire and-adja are permanently cent the buttons are weakened points 3'.

. Thev twister ties-|D are-loopedat their ends at gaged in I the set ;up

. sup- The-purpose e -form boards contacted on s H)" -and to ong thewalers passed through the up- :-*'.'1he. tension applied to twisters l ii according to. theformer :practice mold boards at Hand 'hherein;deflectthe thin :.lmateria1s-used.at 6 and I causing irregularities,

--.particularly-ibulging, "so

:ished. To= avoid;-.-=bulg-ingof the-wall surface e-yvhich'.-.would.-be most ob ntice of: the invention; 2 .large size. rare. boredsi jeotionable in the practhe .holes 312 of-relatively n the uprights 5 and 5--.-in

registration :asi'shown and, if desired-these holes --.mayxbe also formed inwmold boards Band 'L' The twisteri-tiesfll i] are aplaced'inrthe partly completed mold, i. e., are inserted after -the mold board I,

I; 1."; :etc.; lhasbeen set up being :passedout- .1; wardlyu throughaholes cl 4 in the walers' 5 is 'and through the members BJ'and 4','-the latterwhaving --.holes 1! 4'. for.) this .xpurpose, and i the twisters i B :are;1dropped1 to r thebottoms i'of -holes 2-to cause -.:buttons 2105'.-to.engageI'the 'moldvboards 6- and 1 .zadjacentv the.holes. r"FI?he-- loops- Hr. are. formed after assembling. :and the. wedges :i ":2 provide sufficient tension to secure i-theboai dst-directly qtopits uprights without .bending. i 'At the end 0f :the roperation, when stheqmold =is knocke "then-members el 0. are broken :at a! fl""-.- by

d down, twisting the .loopszandi-the end. portions l 5 beyond buttons 0.:.;are i removed: through .holes 12, being taken 401T. with :the. walers and'later removed therefrom.

The. .button -.cavities1and-. hole .gasphalt 0.a.;and 1| 2.-a.

S112 are sealed with The walers are positioned or supported: inany suitable manner by struts or brackets It on the uprights 5 and 5. Figs. '7 and 8 show the plaster I! in position, supported at the bottom by a wood timber known as a plaster ground l8. The floor joists l9 are seated at their ends in the concrete I being assembled with the forms prior to pouring. The space between these forms which receives the concrete is referred to as the form cavity.

As already pointed out, an important saving is accomplished by avoiding the expense of inner form boards and also by avoiding the expense incident to applying and removing the inner form boards or it may be considered that the plaster base is installed and attached to the wall at little or no extra expense because it serves as an essential part of the form, the expense of installation of the same being little or no greater than the original cost plus the cost of installation of the form boards, further the cost of the removal of the form boards is a complete saving, and

finished the plastered concrete wall which results is not only a moisture proof and well insulated wall which is proof against condensation but the plaster is permanently attached and there is no tendency for it to become discolored and detached on account of attack by moisture.

I have thus described specifically and in detail I a preferred form of the invention and the method of applying the same, the description being specific and in detail in order that the manner of constructing, operating and using the invention may be fully understood, however, the details of construction described are capable of wide variation, the specific terms being used in a descriptive rather than in a limiting sense and the scope of the invention being defined in the claims.

base and to support the surface of the concrete in plastic condition, to upright frame members located within said inclosure, employing as the securing means anchoring devices projecting into the mold cavity extending through said sheet material and inserted in the removable frame members, an outer mold being located in suitably spaced relation to the inner mold, pouring the concrete and permitting it to set whereby the anchoring devices are secured in and to the concrete, removing the inner frame members and thereby withdrawing the anchoring devices from the said frame members leaving the anchoring devices and said sheet material affixed to the What I claim as new and desire to secure by Letters Patent is:

1. The method of molding and covering the inner surface, of a concrete wall for buildings and similar enclosures which consists in constructing an inner mold by affixing a sheet of material, which is approximately impervious to the plastic concrete and is also adapted to act as a plaster base, to spaced inner frame members used to support the inner mold and located inside said enclosure, employing as securing means, anchoring devices projecting into the mold cavity and also extending through said sheet material and having a separable engagement with said inner frame members, an outer mold being located in suitably spaced relation to the inner mold, pouring the concrete into the mold cavity between said molds and permitting the concrete to set whereby the anchoring devices are secured in and to the concrete, removing the inner frame members and thus separating them from the anchoring devices leaving the sheet material and anchoring devices affixed to the concrete and applying a plaster like coating to the sheet metal.

2; The method of molding, and covering the inner surface of a concrete wall for buildings and similar inclosures which consists in constructing an inner mold by affixing a sheet of material, which is approximately impervious to the plastic concrete and is also adapted to act as a plaster concrete, deflecting the portions of said anchoring devices formerly inserted in said frame, members and applying a plaster like coating to the sheet material.

3. The method of molding and covering the inner surface of a concrete wall for buildings and similar inclosures which consists in providing an inner mold by afiixing a sheet of material, which is approximately impervious to the plastic concrete and is also adapted to act as a plaster base. and to support a surface of plastic concrete, to suitably spaced inner removable frame members, located within the inclosure and adapted to support the inner mold, employing as the securing means nails having double heads projecting into the mold cavity and having shanks extending oppositely to said heads through said sheet material and into said frame members, an outer mold being located in suitably spaced relation to the inner mold, pouring the concrete and permitting it to set whereby the anchor heads are secured in and to the concrete, removing the inner frame members whereby said shanks are withdrawn from the frame members leaving the sheet material and the anchoring members affixed to the concrete, deflecting said shanks and applying a plaster like coating to the sheet material.

4. The method of molding, and of covering the inner surface of concrete walls, of a building or similar inclosure which consists in providing an inner mold wall by affixing a sheet of material, which is approximately impervious to the plastic concrete and adapted to support a surface of the same, and is also adapted to act as a plaster base, to removable inner frame members, located within said inclosure, employing as securing means nail-like members, having heads and other anchoring means within the mold space, and shanks extending through said sheet material into said removable frame members, an outer mold being located in suitable spaced relation to the inner mold, pouring the concrete into the mold cavity and permitting it to set, whereby the anchoring devices are secured in and to the concrete, and the sheet material is secured t othe concrete, removing the inner frame members thereby withdrawing the anchoring means therefrom and separating the frame members from the sheet material which remains aflixed to the inner surface of the concrete and applying a plastic coating to the sheet material.

FOSTER T. FENTON. 

